Stair Tread

ABSTRACT

A stair tread has a generally planar member that is supported by a horizontal surface of a step. The planar member has a top surface, a bottom surface, a back edge, and a leading edge. The leading edge extends beyond a front edge of the step when the stair tread is positioned on the step. A bull nose is formed on the leading edge of the planar member and extends below the horizontal surface of the step. An adhesive layer disposed on the bottom surface of the planar member adheres the stair tread to the top surface of the step. A face plate may adhere to a riser associated with the step and extend behind the stair tread.

RELATED APPLICATION

The application claims the benefit of U.S. Provisional PatentApplication No. 61/533823 filed Sep. 13, 2011, which is incorporatedherein by reference.

FIELD OF THE INVENTION

The present invention relates generally to stairs, and particularly, tomolded plastic treads for concrete stairs and concrete-filled pan stairsystems.

BACKGROUND

Concrete-filled pan stair systems are commonly used in commercialbuildings, offices, hotels, school buildings, hospitals, apartmentbuildings, and other building structures. In concrete-filled pan stairsystems, stair treads are formed by attaching shallow metal pans tostair stringers, which are then filled with concrete. These types ofstair systems are relatively inexpensive to construct and are mandatedby the American Disabilities Act for many public buildings. However,this construction technique results in an industrial appearance, whichis not suitable for some applications.

SUMMARY

The present invention provides a stair tread for poured concrete stairsand concrete-filled pan stair systems. The stair tread is molded from athermoset polyester to imitate wood, stone, or some other visuallyappealing material. The stair tread comprises a planar member with abull nose. A pressure sensitive adhesive (PSA) may be disposed on asurface of the underside of the stair tread. Upon the application ofpressure, the PSA bonds with a horizontal surface of the step to affixthe stair tread to the step.

Of course, those skilled in the art will appreciate that the presentinvention is not limited to the above contexts or examples, and willrecognize additional features and advantages upon reading the followingdetailed description and upon viewing the accompanying drawings

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 illustrates a set of stairs as viewed from the side with a treadaccording to one embodiment of the present invention.

FIG. 2 is a section view illustrating a stair tread according to a firstembodiment of the present invention.

FIG. 3 is a section view illustrating a stair tread according to asecond embodiment of the present invention.

FIG. 4 is a section view of a face plate for use with the stair tread inFIG. 3.

FIG. 5 illustrates the stair tread of FIG. 3 and face plate of FIG. 4installed on a stair.

DETAILED DESCRIPTION

The present invention provides a stair tread for a step. As seen in FIG.1, a set of stairs 10 has a plurality of steps 12. Each step 12 isformed by a horizontal surface 14 and a riser 16. In this embodiment,the riser 16 comprises a closed riser; however, those skilled in the artwill readily appreciate that the riser 16 may be open. The steps 12 may,for example, comprise a poured concrete stair system or concrete-filledpan stair system.

The stair tread 20 according to the present invention is designed toattach to the horizontal surface 14 of the step 12. The stair treads 20are manufactured separately from the stairs 10, and may comprise, forexample, a thermoset polyester material, such as plastic, that is moldedas a unitary piece. Additionally, the stair treads 20 may be designed toimitate wood, stone, or other natural materials.

FIG. 2 is a close up view illustrating a stair tread 20 in more detail.Each stair tread 20 comprises a generally planar member 22 with a bullnose 24 along the leading edge. The back edge 28 of the planar member 22is inclined to match the angle of the risers 16. As previouslydescribed, the planar member 22 and the bull nose 24 are preferablymanufactured as a single piece; however, this is not required. In someembodiments, the planar member 22 and the bull nose 24 may bemanufactured separately and then joined together using glue or epoxy orany means known in the art.

The bull nose 24 comprises a smooth, rounded edge that extends thelength of the stair tread 20 as seen in FIG. 1. When installed, the bullnose 24 extends beyond and below the horizontal surface 14 of the step12 on which it is installed. The bull nose 24 has a rearwardly facingsurface 26 that butts against the riser 16. In this embodiment, theriser 16 is slightly angled relative to the vertical. The surface 26 ofthe bull nose 24 is preferably inclined to match the inclination of theriser 16. In this embodiment, for example, the surface 26 forms an acuteangle a of about 82° with respect to the underside of the stair tread20.

A pressure sensitive adhesive (PSA) 30 is applied to the underside ofthe planar member 22 for securing the stair tread 20 to the horizontalsurface 14 of a step 12. The PSA 30 bonds the tread 20 to the horizontalsurface 14 when pressure is applied. A peel-away cover protects the PSA30 prior to installation. To install the stair tread 20, the peel-awaycover is removed just prior to attaching the stair tread 20 to thehorizontal surface 14 of the steps 12. Optionally, a PSA 30 may beapplied to the surface 26 of the bull nose 24 to adhere the bull nose 24to the exterior surface of the riser 16.

The stair tread 20 according to the present invention can bepre-manufactured in desired lengths. The stair tread 20 may have analuminum oxide coating to prevent slipping. A sealer and clear coat canbe applied over top of the aluminum oxide coating.

FIG. 3 illustrates a stair tread 40 according to another exemplaryembodiment. The stair tread 40 is designed to be used in conjunctionwith a face plate 60 as shown in FIG. 4. The face plate 60 is designedto cover the riser 16 on a step 12 and the stair tread 40 is designed tocover the horizontal surface of the step 12 as shown in FIG. 5. Althoughnot required, the face plate 60, such as seen in FIG. 5, extends behindthe stair tread 40 such that the stair tread 40 abuts the face plate 60.

The stair tread 40 comprises a generally planar member 42 with a bullnose 44 along the leading edge. The back edge 48 of the planar member 42is inclined to match the angle of the risers 16. The planar member 42and the bull nose 44 may be manufactured as a single piece. In otherembodiments, the planar member 42 and the bull nose 44 may bemanufactured separately, and then joined together to form a unitarymember.

The bull nose 44 comprises a smooth, rounded edge that extends thelength of the stair tread 40. When installed, the bull nose 44 extendsbelow the horizontal surface of the step 12 to which it is installed.The bull nose 44 has an interior surface 46 that butts against the faceplate 60. The interior surface 46 is inclined to match the inclinationof the riser 16. The interior surface 46 includes a channel 50 formedtherein to receive a protrusion 68 on the upper end of the face plate 60as hereinafter described. A pressure sensitive adhesive (PSA) 52 isapplied to the underside of planar member 42 for securing the stairtread 40 to the horizontal surface 14 of a step 12. The PSA 52 bonds thetread 40 to the horizontal surface 14 when pressure is applied. Apeel-away cover protects the PSA 52 prior to installation.

Referring to FIG. 4, the face plate 60 is shown in more detail. The faceplate 60 includes a generally planar member 62. The bottom end 64 andtop end 66 of the face plate 60 are angled to match the angle of therisers 16. The top end 66 includes a rounded protrusion 68 that isconfigured to engage the interior channel 50 on the stair tread 40. Apressure sensitive adhesive (PSA) 70 is applied to the backside of faceplate 60 for securing the face plate 60 to the riser 16 of a step 12.The PSA 70 bonds the face plate 60 to the riser 16 when pressure isapplied. A peel-away cover protects the PSA 70 prior to installation.

FIG. 5 illustrates the stair tread 40 and face plate 60 installed on astair. The face plate 60 is disposed against the surface of a riser 16with the protrusion 68 facing outward. The stair tread 40 is theninstalled on the horizontal surface 14 of the step such that the backedge 48 of planar member 42 butts up against the surface of the faceplate 60. As the stair tread 40 is slid into position, the protrusion 68on the face plate 60 engages the interior channel 50 of the stair tread40. When fully engaged, the protrusion 68 prevents the leading edge ofthe stair tread 40 from lifting.

The present invention may, of course, be carried out in other ways thanthose specifically set forth herein without departing from essentialcharacteristics of the invention. For example, the previous embodimentsdescribe the stair tread as being installed on stairs disposed incommercial buildings. However, the stair tread of the present inventionis not so limited. Those of ordinary skill in the art will readilyappreciate that the stair tread of the present invention may also beinstalled on stairs that are associated with residential buildings suchas houses, for example. The present embodiments are therefore to beconsidered in all respects as illustrative and not restrictive, and allchanges coming within the meaning and equivalency range of the appendedclaims are intended to be embraced therein.

1. A stair tread comprising: a generally planar member configured to besupported by a horizontal surface of a step, said planar member having atop surface, a bottom surface, a back edge, and a leading edge thatextends beyond a front edge of the step when the stair tread ispositioned on the step; a bull nose formed on the leading edge of theplanar member, said bull nose extending below the horizontal surface ofthe step; and an adhesive layer on a bottom surface of the planar memberfor adhering the stair tread to the step.
 2. The stair tread of claim 1wherein the bull nose includes a rearwardly facing surface configured toengage a riser of the step when the stair tread is positioned on thestep.
 3. The stair tread of claim 2 wherein the rearwardly facingsurface is disposed at an angle.
 4. The stair tread of claim 1 whereinthe back edge of the planar member is configured to engage a riser of astep adjacent to the step on which the stair tread is positioned.
 5. Thestair tread of claim 1 wherein the planar member and bull nose areformed as a unitary member.
 6. The stair tread of claim 5 wherein theplanar member and bull nose are made of a thermoplastic material.
 7. Thestair tread of claim 1 wherein the top surface includes a patternimitating a natural material.
 8. The stair tread of claim 7 wherein thepattern comprises a wood grain pattern.
 9. A stair tread assemblycomprising: a stair tread configured to be installed on a horizontalsurface of a step, said stair tread comprising a generally planar memberincluding a bottom surface, a top surface, a back edge, and a leadingedge that extends beyond the step when the stair tread is positioned ona step; a bull nose formed on the leading edge of the planar member ofthe stair tread and configured to extend below the horizontal surface ofthe step when the stair tread is positioned on the step, said bull noseincluding a rearwardly facing surface having a channel formed therein; aface plate configured to be installed on a riser of the step, said faceplate comprising; a generally planar member having a front surface, aback surface, a top edge, and a bottom edge; and a protrusion formed onthe top edge of the planar member of the face plate, said protrusionconfigured to engage within the channel formed in the stair tread whenthe face plate and stair tread are positioned on a step.
 10. The stairtread assembly of claim 9 further comprising a first adhesive layer on abottom surface of the planar member of the stair tread for securing thestair tread to the horizontal surface of the step, and a second adhesivelayer on a back surface of the face plate for securing the face plate tothe riser of the step.
 11. The stair tread assembly of claim 9 whereinthe stair tread and face plate are each unitary members.
 12. The stairtread assembly of claim 11 wherein the stair tread and face plate areeach made of a thermoplastic material.
 13. The stir tread assembly ofclaim 9 wherein a top surface of the stair tread include a patternimitating a natural material.
 14. The stair tread assembly of claim 13wherein the pattern comprises a wood grain pattern.